Low cost high speed titanium and its alloy production

ABSTRACT

A method for refining a titanium metal containing ore such as rutile or ilmenite or mixtures to produce titanium ingots or titanium alloys and compounds of titanium involves production of titanium tetrachloride as a molten slag, by processing the ore in a chlorination procedure and removing various impurities by a distillation or other procedure to form a relatively pure titanium tetrachloride (TiCl 4 ). Thereafter, the titanium tetrachloride is introduced continuously into the focal point of a plasma reactor in a molten magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium environment for the initial reduction of gas phase titanium into molten titanium drops which are collected by a set of skulls. Thereafter, further processing is carried out in a controlled environment and the titanium is heated by plasma guns in order to maximize titanium purity and, in a final optional stage, alloying compounds are added under the same controlled environment and high temperature conditions.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to processing of titanium bearing ores and more specifically to an improved process for low cost and high speed extraction, production and refining of titanium and titanium alloys.

[0002] The present invention is yet another improvement over Dr. Joseph's prior patents, U.S. Pat. No. 5,503,655 of Apr. 2, 1995 as well as U.S. Pat. No. 6,136,060 of Oct. 24, 2000, the disclosures of which are incorporated herein by reference. In the former patent, there is described a process in which a liquid slag containing titanium dioxide is reduced to a mixture of titanium dioxide and iron, the latter separated out to produce about 95% pure titanium dioxide, the balance being impurities. In subsequent processing, the partially pure titanium dioxide is melted and processed to remove any residual iron and other impurities to form titanium dioxide powder.

[0003] In the latter patent, there is disclosed a process for production of titanium and titanium alloys similar to the present process. However, the reduction step in the latter patent is carried out by molten metallic sodium, whereas here, the reductant could be any of magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium. Further, the current process is carried out in an inert gas environment instead of under vacuum conditions as in the latter patent.

[0004] Numerous other disclosures for processing and making titanium alloys are present in the art. Descriptions of some of these are found in the below listed patents:

[0005] U.S. Pat. No. 4,793,854

[0006] U.S. Pat. No. 3,237,254

[0007] U.S. Pat. No. 3,549,353

[0008] U.S. Pat. No. 3,494,804

[0009] U.S. Pat. No. 4,828,608

[0010] U.S. Pat. No. 4,027,722

[0011] U.S. Pat. No. 3,546,348

[0012] U.S. Pat. No. 2,997,760

[0013] U.S. Pat. No. 3,210,454

[0014] U.S. Pat. No. 3,343,828

[0015] U.S. Pat. No. 4,035,574

[0016] U.S. Pat. No. 4,838,340

[0017] U.S. Pat. No. 3,467,167

[0018] U.S. Pat. No. 2,727,937

[0019] U.S. Pat. No. 3,342,250

[0020] U.S. Pat. No. 4,488,902

[0021] U.S. Pat. No. 3,764,297

[0022] British Pat. No. 809444

[0023] U.S. Pat. No. 3,607,222

[0024] Canadian Pat. No. 549299

[0025] It is known that titanium, especially some of its alloys, e.g., titanium-aluminum-vanadium (TiAl₆V₄) are important because they are ideally suited for a wide variety of applications in the aerospace, aircraft, military, and automotive fields. Titanium and its alloys, including that mentioned, combine the attractive properties of high strength and light weight with resistance to corrosion and stability under high temperatures. For example, titanium is very strong but only about 60% as dense as iron and parts made of titanium will weigh only 60% as much as the same part made of steel. While titanium is relatively easy to fabricate, there are numerous impediments to its widespread use. Refining titanium is energy intensive and involves significant costs in handling due to the need for toxic chemicals for its refining. Furthermore, in refining titanium, there is a high cost involved in disposing of the toxic byproducts produced in the refinery process. Finally, there are the geopolitical aspects of having to obtain most of the semi-processed titanium sponge from former communist and communist countries as well as from the Republic of South Africa.

[0026] Thus, it is a primary object of this invention to provide an improved and cost effective process for the production of high purity titanium and its alloys from a starting ore containing titanium, preferably in an oxide form.

[0027] Another object of the present invention is the conversion of a titanium bearing ore such as rutile or ilmenite to an essentially pure titanium tetrachloride followed by reduction to titanium which is then followed by refining of the titanium to a pure state and optionally alloying the same.

[0028] Another object of this invention is the provision of an improved process for the production of a high purity titanium-aluminum-vanadium alloy such as TiAl₆V₄.

[0029] Another object of this invention is to process molten titanium under conditions which prevent contact with the environment, and processing the molten metal under at least two controlled environment condition phases to outgas the metal and optionally to produce a titanium-aluminum-vanadium alloy.

[0030] These objects and features of the present invention will become more apparent from the following detailed description which provides detailed information regarding both the process and apparatus and which is for purposes of illustration and should not be construed as a limitation on the present invention.

[0031] The process previously patented by Dr. Joseph utilizes sodium as a reductant, and produces high-grade titanium metal under ideal conditions. Alternatively, magnesium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium can be used as the reductant instead of sodium. For example, the recycle of magnesium by electrolysis of magnesium chloride is known technology. It has been noted that both sodium and magnesium are effective reductants. Their free energies of formation being more negative than that of TiCl₄.

[0032] The choice of reductant is based on:

[0033] Suitability for reaction—thermodynamics and kinetics;

[0034] Cost of the metal;

[0035] Ease of delivery or handling;

[0036] Disengagement of the products; and

[0037] Safety.

[0038] The following database of characteristics is useful for making this selection: Component Melting Point ° C. Boiling Point ° C. Na 98 882 Mg 650 1105 Ti 1667 3285 TiCl₄ −25 137 NaCl 801 1465 MgCl₂ 714 1418 TiCl₃ 730 750

[0039] The thermodynamics show no real benefit for one reactant over the other as far as can be discerned from the equilibrium considerations. In the Kroll and Hunter processes (see Hawley's Condensed Chemical Dictionary (11th ed. 1987)) it is clear that either reaction is possible and no data has been found to support a preference for one over the other.

[0040] Kinetic data is even harder to come by. Tisdale et al. give some useful indicators that the reaction of titanium tetrachloride with magnesium metal is sufficiently fast in the vapor phase at 1150-1250° C. to preclude concerns over excessively long reaction times for a continuous process. “Vapor phase titanium production”, D. G. Tisdale, J. M. Toguri, and W. Curlook, CIM Bulletin, March 1997:159-163.

[0041] The cost of the metal is a major consideration as the objective is to provide a process route that will provide more favorable economics. One determinant is that the reaction with magnesium needs half the molar quantity of reductant as the sodium route. This means that it is also energetically favored, as there is less reductant to heat up to reaction temperatures. The fact that magnesium is currently in abundance and roughly half the cost of the sodium per pound or kilogram is a minor point in its favor.

[0042] Another important factor for a scaled-up facility is that the economics of recycling magnesium chloride ultimately reduces the operating cost of the system. Magnesium metal can be relatively easily recovered from the magnesium chloride product by electrolysis to yield chorine and magnesium metal. It is believed that the sodium recovery operation is more problematic. It is also less likely that one could obtain over-the-fence processing of the sodium chloride back to sodium metal and chlorine. With the magnesium route, in the first instance, the plant can sell the magnesium chloride for recovery by others or indeed for use as a chemical, which would defray operating costs.

[0043] Both magnesium and sodium have their problems and great care should be exercised in their handling. Sodium melts at a much lower temperature: so maintaining feed systems in the molten state is simpler. It is however more reactive with water and has to be stored under paraffin, as it will oxidize rapidly in air. Magnesium on the other hand can be delivered as ingots or “bricks” and is stable at room temperature. The products of the reactions have their respective advantages and disadvantages. By reference to the database on melting and boiling points of each and any unreacted metal, it can be seen that the operating temperature of the reactor has to be held above the condensation point to enable good separation and availability of the equipment.

[0044] To evacuate the process stream of product chloride and metal requires an operating temperature of at least 1465° C. Alternatively, sufficient flushing gas such as argon must be provided to assure that the walls of the vessel are above the dew point determined by the vapor pressure of any residual chloride or metal in this gas stream.

[0045] While sodium metal is clearly more volatile than magnesium and therefore itself would be easily stripped from the melt at high temperatures, its has a marginally higher boiling point than magnesium chloride. There is therefore benefit in operation with the magnesium system.

[0046] Development of a low cost, high speed, continuous or near-continuous process of producing a high-grade titanium product which is essentially pure, represents a great improvement in the field of metallurgy, and satisfies a long felt need for a commercial process with a high potential capacity, but which is less labor intensive. Further, any component which will make the process even more cost effective and efficient is beneficial.

SUMMARY OF THE INVENTION

[0047] The present invention is a process for refining titanium containing ore and more particularly a sequence which involves converting the titanium ore to titanium tetrachloride, the latter continuously reduced to titanium in a plasma reactor in the presence of molten magnesium which is also continuously fed and finally processed to a relatively high purity while molten and under controlled environment conditions followed optionally by alloying with other metals such as aluminum and vanadium.

[0048] In the portion of the process which produces titanium tetrachloride, many of the impurities such as iron chloride and vanadium are removed and the resulting product is of markedly reduced impurities, e.g., less than four parts per billion.

[0049] The reduction of titanium tetrachloride is carried out in the presence of molten magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium and at atmospheric pressure in a plasma reactor. Thereafter, the molten titanium is processed under conditions of atmospheric pressure approximately 760 Torr and elevated temperatures, an operation which is carried out in stages. It is in the second stage that alloying optionally may take place.

[0050] An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and description of a preferred embodiment.

BRIEF DESCRIPTION OF THE DRA WINGS

[0051]FIG. 1 is a diagrammatic illustration of the general steps for production of titanium alloy from titanium ore in accordance with the present invention;

[0052]FIG. 2 is a process flow sheet for the production of titanium tetrachloride in accordance with this invention;

[0053]FIG. 3 is a sketch of the plasma reactor for the reduction of titanium tetrachloride in accordance with this invention;

[0054]FIG. 4 is an illustration of the titanium tetrachloride supply system used with the plasma reactor of FIG. 3 in accordance with this invention; and

[0055]FIG. 5 is an illustration of the apparatus for titanium alloying and purification in accordance with this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0056] While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.

[0057] Referring to the drawings which illustrate a preferred embodiment of this invention, the general flow diagram of FIG. 1 shows the general sequence of steps. The first step 10 includes the formation of essentially pure TiCl₄ from a starting titanium bearing ore such as rutile or ilmenite or mixtures of ores. Rutile is an ore containing titanium and oxygen (TiO₂) while ilmenite is an ore containing iron, titanium and oxygen (TiO₂Fe₂O₃). For the purposes of this invention, any titanium containing ore or mixtures of ores preferably with oxygen, with or without other metals, may be used as the starting ore. The titanium ore is dressed in a conventional manner to produce an ore concentrate. In effect, the first general step 10 includes conversion of the starting ore to titanium tetrachloride preferably having less than 4 parts per billion of metallic impurities since the latter are difficult to remove in later processing. Generally, this step includes chlorination of the ore to form titanium tetrachloride.

[0058] The next general step 12 involves conversion of the essentially pure titanium tetrachloride to titanium metal by plasma arc treatment in a chemical reduction process resulting in the reduction of the TiCl₄ to titanium and 2XCl₂, where X is beryllium, magnesium, calcium, strontium, barium or, radium, or 4YCl, where Y is hydrogen, lithium, sodium, potassium, rubidium, cesium or francium. In this second general step 12, a plasma reactor 40 (to be described) is used in which magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium is melted if necessary, and is injected continuously into a reaction chamber with heated titanium tetrachloride resulting in the formation of titanium metal and 2XCl₂, where X is beryllium, magnesium, calcium, strontium, barium or, radium, or 4YCl, where Y is hydrogen, lithium, sodium, potassium, rubidium, cesium or francium.

[0059] The third general step 15 involves processing the titanium from the second step under a controlled environment in which the titanium is heated and kept molten by plasma guns 130 (to be described) and at controlled environment conditions resulting in a very pure titanium metal which can be cast into ingots or converted to an aluminum-vanadium alloy while the titanium metal is in liquid form. In this third general step 15, dissolved gases such as hydrogen and chlorine are removed by out gassing. Since out gassing generally cannot remove oxygen, nitrogen and carbon, the plasma arc use of an inert gas environment tends to prevent these latter materials from becoming contaminants.

[0060]FIG. 2 illustrates the details of the process involved in the first general step 10 shown in FIG. 1 for the production of titanium tetrachloride from a suitable ore. As shown, a titanium and oxygen bearing ore 17 such as rutile or ilmenite or mixtures, is dressed 16 with petroleum coke 18 and chlorine gas 19 and processed in a chlorination step 20 at an elevated temperature. After chlorination 20, the mixture contains titanium tetrachloride and iron chloride and other impurities which are separated out in a separation and condensation step 22. The impurities are separated at 24 resulting in the formation of a crude titanium tetrachloride as shown at 25.

[0061] The crude titanium tetrachloride 25 is then processed at 28 to remove vanadium, as shown at 29, followed by distillation at 30, again at an elevated temperature, to remove silicon chloride as shown at 32. After removal of vanadium 29, the concentration of impurities is preferably below about 4 parts per billion. The result is essentially pure titanium tetrachloride (TiCl₄).

[0062] Thus, the first detail step within the first general step 10 involves ore dressing 16 to produce an ore concentrate. The second detail step involves chlorination 20 of the ore concentrate to form crude metal 25. This second detail step involves two separate sub-steps:

[0063] (a) Conversion of the concentrate to crude TiCl₄ 25. This is done by the chlorination process 20 represented by the reaction:

TiO₂(s)+2Cl₂(g)+2C(s)→TiCl₄(g)+2CO(g)

[0064] The chlorination process 20 is carried out in a chlorinator. With rutile ores, in the case of ilmenite, iron chloride is also formed and has to be removed as a separate step 22.

[0065] (b) The crude TiCl₄ 25 is further purified 28, 30 to remove vanadium 29 and silicon 32 impurities. The final product is pure TiCl₄. All the metallic impurities have to be removed in this step since they cannot be removed subsequently.

[0066] The next general step 12 is the plasma arc reduction of titanium tetrachloride in the presence of gaseous hydrogen or molten metallic magnesium, sodium, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium to produce titanium and 2XCl₂, where X is beryllium, magnesium, calcium, strontium, barium or, radium, or 4YCl, where Y is hydrogen, lithium, sodium, potassium, rubidium, cesium or francium according to the equation:

TiCl₄+2X→Ti+2XCl₂

[0067] where X is beryllium, magnesium, calcium, strontium, barium or, radium, or

[0068] TiCl₄+4Y→Ti+4YCl

[0069] where Y is hydrogen, lithium, sodium, potassium, rubidium, cesium or francium.

[0070] The plasma reduction 12 may be carried out in an apparatus 40 illustrated in FIG. 3 and referred to as a plasma reactor utilizing argon or helium. The reactor 40 includes basically two zones. The upper zone 41 is at atmospheric pressure and the lower zone 43 is the input side of the reduction and refining apparatus (FIG. 5) at a controlled pressure of about 760 Torr, with later stages keeping the same pressure. The two zones 41, 43 are separated by a flange 45, which holds a collector crucible 110 (to be described).

[0071] The top portion 50 of the reactor 40 includes an injection port 51 through which gaseous hydrogen or metallic magnesium, sodium, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium is introduced into the reactor 40. Surrounding the top portion 50 is a graphite block 54 for high temperature resistance. The gaseous hydrogen or metallic magnesium, sodium, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium is heated to a liquid by a plurality of torches 52 arranged at a tilted down 60 degree angle and disposed circumferentially at 120 degrees from each other, two being shown at 52, and located vertically below the magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium injection port 51. The magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium is introduced at the focal point 53 of the torches 52, as illustrated diagrammatically. Located vertically below the torches 52 is a titanium tetrachloride injection port 55 such that the heated and gaseous hydrogen or molten metallic magnesium, sodium, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium comes into intimate contact with the injected titanium tetrachloride and is intermixed therewith for reaction. Located vertically below the titanium tetrachloride injection port 55 is a dual reactor section 57, 58, including a graphite liner 54 a, for reaction between the molten magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium and the heated titanium tetrachloride. Graphite rings 56 are used for temperature resistance, and within the reactor sections 57, 58 are temperature resistant graphite columns 56 a. Vertically below the reactor sections 57, 58 is a separator section 59 through which the 2XCl₂ or 4YCl is withdrawn through an exhaust system (not shown). Formed titanium metal in the form of molten titanium droplets passes from the separator 59 into the crucible 110 in section 43 of the further processing station 100 to be described.

[0072] A titanium tetrachloride supply system 60 for titanium tetrachloride injection into the plasma reactor 40 is illustrated diagrammatically in FIG. 4. The supply system 60 includes a sealed titanium tetrachloride reservoir tank 62 which receives relatively pure titanium tetrachloride from the process output 43 of FIG. 2. The tank 62 includes an inert gas supply system 63 for argon or helium gas, for example, supplied from a pressurized gas source such as an argon or helium gas tank (not shown) through a two-stage pressure regulator. The tank 62 also includes an in-line pressure relief valve 66 which may vent to a hood and a pressure gage 64 to monitor the internal pressure of the tank 62. The tank 62 also includes an outlet system 65 whose output is connected to a titanium tetrachloride boiler vessel 70.

[0073] The outlet system 65 includes a series of manually operated valves 71, 72 and Swagelok® unions 74 for disconnecting the reservoir tank 62 from the remainder of the system 60. Down stream of the valves 71, 72 is a flowmeter 75 controlled by a manually operated valve 77. The outlet 78 of the flowmeter is connected as the inlet at the bottom of the boiler vessel 70. The boiler vessel 70 itself includes an inner heater section 80 and an outer titanium tetrachloride heater chamber 82. The heater chamber 82 surrounds the heater section 80 and is sealed relative thereto. The titanium tetrachloride is fed into the heater chamber 82 under a blanket of argon or helium gas.

[0074] The heater section 80 includes an immersion heater assembly 85 which includes an immersion heater device 86 which extends into the heater section 80 and which is supported at the top of the tank 70 by means well known in the art. The immersion heater 86 may be any one of the immersion heaters well known in the art. As shown, the immersion heater 86 is spaced from the wall forming the heater chamber 82 and is preferably filled with a heat transfer fluid for effective transmission of heat from the immersion heater 86 to the wall of the chamber 82.

[0075] Surrounding the outer wall of the tank 70 is a heater tape unit 90 connected to a source of electrical power through a junction 91. Mounted at the top of the tank 70 and communicating with the heater chamber 82 is an in-line pressure relief valve 92 which vents to a hood. The tank 70 and the heater chamber 82 include an outlet 93. The exit side 95 of the outlet forms the inlet injection nozzle for the injector 55 of the plasma reactor 40 of FIG. 3. The outlet system 93 from tank 70 includes heating tapes 96 supplied with power from a junction 97. Downstream of the tapes 96 is an argon or helium purge valve 98 controlled by a three way electrically operated solenoid valve 99.

[0076] The apparatus 100 for reduction and refining and/or alloying of the titanium metal output from the device of FIG. 2 is shown in FIG. 5. The apparatus 100 includes multiple chambers 102, 104 separated into two general zones by a gate valve 105 (as shown). The zone 102 on the left contains a titanium reduction plasma gun 107, such as a hydrogen argon plasma gun and additional plasma guns 108 for heating the titanium carrying ceramic vessel or crucible 110 and the molten titanium as it is produced. Zone 102 is at atmospheric pressure, e.g. 760 Torr, and receives molten titanium, in the form of titanium droplets, from the output 43 of the reactor 40. The liquid titanium droplets entering section 102 at 107 are heated by the plasma gun 108 and the gun output impinges on a molten titanium pool in the ceramic vessel or crucible 110 provided with a water cooled copper insert (not shown) on which titanium has previously solidified on the crucible walls to form a skull or solidified titanium coating 114 of essentially pure titanium metal. The titanium skull 114 prevents the molten titanium from contacting the bare walls of the ceramic crucible 110 which would result in reaction between titanium and the ceramic with resultant contamination of the titanium. Thus, incoming molten titanium contacts the solid titanium coating 114 of the crucible 110, the coating 114 being maintained solid by the water cooled insert in the ceramic crucible 110.

[0077] The zone 104 on the right of zone 102 is at 760 Torr pressure and contains a water-cooled copper hearth 116 on which a titanium skull 118 has been previously formed inside the copper hearth 116. The hearth 116 may be cooled by interior water cooling pipes, not shown. There are multiple sections in this zone: the first section 120 at 760 Torr; the next and successive section 122 is at the same pressure as the first section, e.g., 760 Torr, the final section 122 including the cold hearth 116 having a lip 123 over which the molten metal flows to be cast into a retractable ingot mold 125. Plasma guns 130 keep the titanium molten in each of these sections. Alloying elements can be introduced into the second section 122 operating at 760 Torr so that an alloy, as previously described, may be formed. To form the alloy mentioned, powdered aluminum in an amount of 6% by weight and powdered vanadium in an amount of 4% by weight are introduced into the chamber 122. The flow rate through the sections 120, 122 has to be a constant if the proper amount of alloys are to be introduced to meet alloy specifications.

[0078] There may be 1 to 3 ceramic vessels or crucibles 110, 110 a with titanium skulls 114, 114 a, formed as described. The ceramic crucibles 110, 110 a are positioned and supported on a table 135 which can be rotated 180 degrees so that the crucible 110, 110 a full of molten titanium can be swung from zone 102 into the left part of zone 104 (or section 120). There is also a tilt mechanism 138 in the left position of zone 104 (or section 120) which permits the molten titanium to be gradually poured over the sloping hearth 116 and flow from left to right and be cast into an ingot in mold 125. As shown, each of sections 120 and 122 includes out ports 140 for degassing control.

[0079] With this design, the reduced titanium metal collection rate in zone 102 is independent of the flow rate on the hearth 116 in zone 104. Since two vastly different technologies are operating in the zones 102 and 104, it is almost impossible to match the reduction rate in the right zone 102 to the flow rate on the hearth 116 in the left zone 104.

[0080] In operation, the first step is to turn on the plasma guns 108 and melt the surface of the skull 114 in zone 102. In the next step, the plasma reduction gun 107 is turned on and the newly reduced titanium is sprayed onto the molten surface of the skull 114 to fill it up.

[0081] Once the skull 114 is filled, the succeeding step is to open the gate valve 105 between zones 102 and 104 and swing the crucible 110 full of molten titanium to zone 104 while an empty skull 114 swings to position in zone 102. Alternate arrangements as may be apparent to those skilled in the art may also be used for this operation. The next step is to close the gate valve 105 isolating the two zones 102 and 104.

[0082] Following the closure of the gate valve 105, the plasma guns 130 in zone 104 are turned on to melt the surface of the skull 118 in the sloping hearth 116. The crucible 110 a full of molten titanium is tilted and poured at a steady rate onto the hearth 116 so that the gases, chlorine and hydrogen, are removed and the titanium is cast into the ingot mold 125. The rate at which the metal is poured over the hearth 116 depends on the quantity of gases present in the titanium from the reduction step. The larger this quantity, the slower the rate so as to give enough time for degassing to occur.

[0083] While the preceding step is occurring in zone 104, the first step is operational in zone 102.

[0084] The virtue of this arrangement is that the processing rates in the left 102 and right 104 zones can be controlled independently of each other to achieve an overall steady production rate.

[0085] This process produces reduced titanium free from dissolved impurities, i.e., chlorine, oxygen, nitrogen, carbon, and hydrogen. Chlorine and hydrogen can be readily removed by exposing the molten titanium surface to high velocity argon or helium plasma, while keeping the titanium sufficiently hot so that it can be cast as an ingot after the degassing operation. As noted, oxygen, nitrogen and carbon cannot be removed in this late stage and hence must be kept out of the titanium by carrying out all processing in an environment where the partial pressures of these gases is very low, i.e., in an inert atmosphere, taking great care that there are no leaks to or from the atmosphere in any of the processing vessels by overflow of argon or helium gas.

[0086] Thus, one of the advantages of this invention is that the plasma reactor 102 and the reduction refining station 104 are basically one integrated apparatus 100. In this way the reduced titanium tetrachloride in the form of molten titanium droplets exits the reactor 40 directly to the second processing stage 100. The transition zone 43 from the reactor 40 is between the reactor 40 and the reducing refining zones 102, 104 and thus the molten drops of titanium are not exposed to fresh ambient environment or at least the exposure to fresh ambient environment is minimized. The purity of the plasma gas, argon or helium, were chosen to maximize the purity of the titanium.

[0087] In effect, from the time of the formation of the molten titanium, the metal is under controlled conditions or inert gas so that the partial pressures of the gases which are difficult to outgas are kept at a minimum. This is achieved by a single integrated apparatus 100 so that the molten titanium metal can be handled and transferred within a controlled environment provided by a single contained apparatus 100 which is effective not only to maintain environmental conditions surrounding the molten titanium under control, but also to exclude the gases which are difficult to outgas.

[0088] An additional and valuable option is the ability to alloy the titanium while it is still molten and make a much more valuable titanium alloy, e.g., TiAl₆V₄. This may be accomplished in the zone 104 side of the device.

[0089] Another advantage of this invention is the formation of essentially pure titanium tetrachloride which is then processed to provide essentially pure titanium metal which can be alloyed, as desired. Moreover, while the starting material is a titanium containing ore 17, this is preferred as opposed to the use of titanium dioxide powders since the latter are relatively expensive and may contain impurities which may be difficult to remove and which may adversely impact the overall purity of the finial titanium product. Another advantage of the present invention is that the final refining and alloying operation is carried out in a single device 100, the low pressure units of which are under controlled atmosphere conditions, i.e., inert gas environment. These atmospheric conditions are relatively benign in the sense that the atmosphere with which the molten titanium is in contact does not include contaminating gas or gases. In this way the purity of the final product is not compromised by exposure to ambient air and the contaminants in air.

[0090] It will be apparent to those skilled in the art from the above detailed description and drawings of the preferred form of this invention that various changes and modifications may be made without departing from the spirit and scope of this invention.

[0091] The following reference numerals are used on FIGS. 1 through 5:

[0092]10 Formation of essentially pure titanium tetrachloride from a starting titanium bearing ore;

[0093]12 Conversion of the essentially pure titanium tetrachloride to titanium metal by plasma arc treatment;

[0094]15 Processing of titanium under controlled conditions in which it is heated and kept molten by plasma guns and at progressively higher control conditions resulting in a very pure titanium metal;

[0095]16 Dressing of the ore to produce an ore concentrate;

[0096]17 A titanium and oxygen bearing ore such as rutile or ilmenite or mixtures;

[0097]18 Petroleum coke;

[0098]19 Chlorine gas;

[0099]20 Chlorination;

[0100]22 Separation and condensation of iron chloride and other impurities;

[0101]24 Separated impurities;

[0102]25 Crude titanium tetrachloride;

[0103]28 Crude titanium tetrachloride processed to remove vanadium;

[0104]29 Removed vanadium;

[0105]30 Distillation to remove silicon chloride;

[0106]32 Removed silicon;

[0107]40 Plasma reactor;

[0108]41 Upper zone at atmospheric pressure;

[0109]43 Lower zone at controlled pressure of about 760 Torr with later stages under controlled conditions;

[0110]45 Flange separating upper and lower zones;

[0111]50 Top portion of plasma reactor;

[0112]51 Injection port;

[0113]52 Plurality of torches;

[0114]53 Focal point of torches;

[0115]54 Graphite block;

[0116]54 a Graphite liner;

[0117]55 Titanium tetrachloride injection port;

[0118]56 Graphite ring;

[0119]56 a Graphite column;

[0120]57 Reactor section for reaction between molten magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium and heated titanium tetrachloride;

[0121]58 Reactor section for reaction between molten magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium and heated titanium tetrachloride;

[0122]59 Separator section;

[0123]60 Supply system for titanium tetrachloride injection into plasma reactor;

[0124]62 Sealed titanium tetrachloride reservoir tank;

[0125]63 Inert gas supply system for argon or helium gas, for example;

[0126]64 Pressure gage to monitor internal pressure of tank;

[0127]65 Outlet system whose output is connected to 70;

[0128]66 In-line pressure relief valve;

[0129]70 Titanium tetrachloride boiler vessel;

[0130]71 Manually operated valve;

[0131]72 Manually operated valve;

[0132]74 Swagelok® unions;

[0133]75 Flowmeter controlled by 77;

[0134]77 Manually operated valve;

[0135]78 Outlet of flowmeter connected as inlet to boiler vessel;

[0136]80 Inner heater section of boiler vessel;

[0137]82 Outer titanium tetrachloride heater chamber;

[0138]85 Immersion heater assembly;

[0139]86 Immersion heater device;

[0140]90 Heater tape unit connected to source of electrical power;

[0141]91 Junction to electrical control unit;

[0142]92 In-line pressure relief valve;

[0143]93 Outlet;

[0144]95 Exit side of outlet;

[0145]96 Heating tapes for outlet system;

[0146]97 Junction supplying power;

[0147]98 Argon or helium purge valve;

[0148]99 Three way electrically operated solenoid valve;

[0149]100 Apparatus for titanium reduction and purification;

[0150]102 Pressure zone on left at 760 Torr;

[0151]104 Pressure zone on right at 760 Torr;

[0152]105 Gate valve separating zones 102 and 104;

[0153]107 Titanium reduction plasma gun, such as hydrogen argon plasma gun;

[0154]108 Additional plasma guns for heating titanium carrying skull and molten titanium;

[0155]110 Titanium carrying ceramic vessel or crucible;

[0156]110 a Titanium carrying ceramic vessel or crucible;

[0157]114 Solidified titanium coating forming skull inside ceramic vessel or crucible;

[0158]114 a Solidified titanium coating forming skull inside ceramic vessel or crucible;

[0159]116 Water cooled copper hearth;

[0160]118 Solidified titanium coating forming skull inside water cooled copper hearth;

[0161]120 First section within zone 104 at controlled pressure;

[0162] 122 Second section within zone 104 at controlled pressure;

[0163]123 Lip over which molten metal flows;

[0164]125 Retractable ingot mold;

[0165]130 Plasma guns;

[0166]135 Table which can be rotated 180 degrees;

[0167]138 Tilt mechanism; and

[0168]140 Out port for outgas control.

[0169] Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof.

[0170] It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention. 

What is claimed is:
 1. A process for the production of titanium metal and alloys thereof comprising the steps of: a. processing titanium containing ore to form essentially pure titanium tetrachloride, said processing step including the steps of: i. chlorinating the titanium bearing ore to form a titanium tetrachloride mixture containing as impurities at least iron chloride, vanadium and silicon chloride; ii. condensing and separating the mixture to remove the iron chloride to form a crude titanium tetrachloride mixture; iii. removing the vanadium present in the mixture; iv. distilling the resultant titanium tetrachloride to remove the silicon chloride to form a titanium tetrachloride material having less than about four parts per billion of impurities; b. reacting the titanium tetrachloride material continuously with a reductant selected from the group consisting of magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium and radium while heating with torches to reduce the titanium tetrachloride material to molten titanium metal; c. processing the thus produced molten titanium metal under controlled atmospheric conditions to effect out gassing of the molten titanium metal; said processing of the molten titanium metal including a first and second processing phase at elevated temperature and separate levels of controlled atmospheric conditions; said second phase being conducted at atmospheric pressure with an environment of inert gas selected from the group consisting of argon and helium and optionally including the step of alloying the molten titanium metal to form a titanium-vanadium alloy; and d. recovering essentially the pure titanium metal or alloy.
 2. A process as set forth in claim 1 wherein the step of reacting the titanium tetrachloride material includes the step of introducing the titanium tetrachloride material continuously into the focal point of the torches for reaction with said reductant.
 3. A process as set forth in claim 1 wherein the conversion of the titanium tetrachloride material to titanium metal is conducted at ambient atmospheric pressure, and said titanium metal is transferred from an ambient atmospheric pressure environment to a controlled environment for processing of the molten titanium metal for out gassing of hydrogen and chlorine gas.
 4. A process as set forth in claim 3, wherein said controlled environment is a gas selected from the group consisting of argon and helium.
 5. A process as set forth in claim 1 wherein said titanium ore is selected from the group consisting of rutile and ilmenite and mixtures thereof.
 6. A process as set forth in claim 1 wherein the step of transferring the formed titanium metal from the reacting step to the processing step of two phases is conducted under controlled environmental conditions to reduce contamination by the gases which are difficult to outgas.
 7. A process as set forth in claim 6, wherein said controlled environmental conditions is a gas selected from the group consisting of argon and helium.
 8. A process as set forth in claim 1 wherein aluminum and vanadium are introduced into the molten titanium during said second phase processing in a controlled environment to produce a titanium-aluminum-vanadium alloy.
 9. A process as set forth in claim 8, wherein said controlled environment is a gas selected from the group consisting of argon and helium.
 10. A process as set forth in claim 6 wherein said aluminum is introduced in an amount of 6% by weight and the vanadium is introduced in an amount of 4% by weight.
 11. A process as set forth in claim 1 wherein said processing of the molten titanium metal includes receiving the said molten titanium metal in at least one skull in the first processing phase and causing said molten titanium metal in the first processing phase to be transferred to the second processing phase, and maintaining said titanium in a molten state by heating the same with at least one plasma gun.
 12. A process as set forth in claim 1 wherein the molten titanium from the reacting step is heated by a hydrogen argon plasma gun before the processing step. 